Bedding product packaging and process

ABSTRACT

Packaged bedding products and processes for forming the packaged bedding product generally include a first plastic film, a second plastic film, a first seam joining the first plastic film to the second plastic film, wherein the first seam is disposed about a periphery of the bedding product; at least one second seam joining an end of the first plastic film to an end of the second plastic film, wherein the at least one second seam is spaced apart from the first seam to define excess plastic film material therebetween, and wherein the at least one second seam and excess plastic film material is provided at one or more of the opposed end surfaces and/or one or more of the opposed side surfaces of the bedding product; and one or more gripper openings disposed in the excess plastic film material.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a NON-PROVISIONAL of and claims the benefit of U.S. Application No. 62/108,746, filed Jan. 28, 2015, which is incorporated herein by reference in its entirety.

BACKGROUND

The present disclosure generally relates to packaging and protective covering, and more particularly, to packaging for bedding product or other products of similar characteristics, shapes or dimensions.

The packaging of bedding products for shipping, distribution, handling and eventual sale presents a formidable challenge given the size and nature of the product. For example, mattresses are generally considered too large for practical packaging in a separate container such as a box, yet must have substantial protection from damage and soiling to maintain the “as new” condition required for retail marketing and sale. This has led to the widespread use of heavier gauge plastic film as a wrapping material, which encapsulates and protects the mattress from the external environment. The formation of a plastic film package about a mattress has been automated, as described for example, in U.S. Pat. Nos. 5,934,041, 6,178,723 and 6,273,257. These packages typically produce a single fused seam of the plastic sheet material about the entire perimeter of the mattress which, although strong enough to keep the sealed plastic package intact, does not address the difficult in handling a large, heavy and flexible product such as the mattress.

Prior art FIG. 1 depicts a mattress M, which may be of any of the custom or conventional sizes made in the U.S. or in other countries of the world, which may be enclosed in a bag-like structure 10, as shown in prior art FIG. 1. The material of the bag 12 may be any material which is suitable for packaging, which preferably provides a sufficiently durable barrier to dirt or debris coming into direct contact with the mattress M, and which resists mechanical damage to some degree, and which can also mold up to forces and stresses applied in the routine handling of a mattress so packaged. The bag 12 is also referred to by those skilled in the art as a “barrier layer”. When manufactured using two sheets of plastic, a seal 14 is disposed about the periphery joining the two sheets of plastic to form the bag. The bag as sealed is generally configured to conform and encapsulate the mattress with minimal excess material.

Once sealed in the plastic, the mattress must then be manually moved. However, because such packaging has no built-in gripping points, the plastic material is further stressed by gripping a section of the material by the handlers, which can lead to tears. Once the plastic is torn, either as a result of handling or from abrasion, the mattress upholstery is readily exposed to soiling and damage, which significantly reduces the retail value or even prevents retail sale of the product. Given the substantial cost and handling requirements of these types of products, returns and recalls due to failure of the packaging are extremely costly to the manufacturer.

BRIEF SUMMARY

Disclosed herein are packaged bedding products and processes for forming the bedding product package. In one embodiment, a packaged bedding product having a depth defined between opposed first and second surfaces, a length defined between a pair of opposed end surfaces and a width defined between a pair of opposed side surfaces, said bedding product being encased in a plastic film package comprises a first plastic film; a second plastic film; a first seam joining the first plastic film to the second plastic film, wherein the first seam is disposed about a periphery of the bedding product; at least one second seam joining an end of the first plastic film to an end of the second plastic film, wherein the at least one second seam is spaced apart from the first seam to define excess plastic film material therebetween, and wherein the at least one second seam and excess plastic film material is provided at one or more of the opposed end surfaces and/or one or more of the opposed side surfaces of the bedding product; and one or more gripper openings disposed in the excess plastic film material.

A process of forming a packaged bedding product having a generally planar first surface and a parallel generally planar second surface comprises simultaneously passing a first web and a second web of plastic film past the first and second surfaces on opposite sides of the bedding product; cutting the first and second webs so as to create first and second pieces of the plastic film about the bedding product; joining the first and second pieces of plastic film together about a periphery of the bedding product to form a first seam enclosing the bedding product in a plastic film package; joining an end of the first piece to an end of the second piece to form at least one second seam, wherein the at least one second seam is spaced apart from the first seam to define excess plastic film material therebetween; and forming hand-hold openings in the excess material.

The disclosure may be understood more readily by reference to the following detailed description of the various features of the disclosure and the examples included therein.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Prior art FIG. 1 illustrates a perspective view of a mattress encapsulated in a plastic wrap.

FIG. 2 is a perspective view of first and second pieces of extruded plastic film located above and below a bedding product.

FIG. 3 is a perspective view of a bedding product individually wrapped in a plastic film package after the first and second pieces of extruded plastic film shown in FIG. 2 are welded together.

DETAILED DESCRIPTION

The mattress packaging and process of the present disclosure generally includes a plastic wrapping or bag with excess material at least along opposing peripheral sides of the mattress, wherein the excess material is configured with openings to permit gripping and handling of the mattress. The mattress packaging and process generally includes forming two spaced apart weld seams in the excess material and forming gripper openings (i.e., hand-hold openings) between the spaced apart weld seams. Advantageously, the mattress packaging and process provide sufficient protection to the mattress and permits the packaged mattress to be easily handled and carried. Although the disclosure is described with reference to the packaging and protection of a mattress M, the packaging concepts are equally applicable to other types of complimentary or comparable products such as foam or foldable mattress or cushions, foundations or box springs or similarly configured home furnishing articles.

Turning now to FIG. 2, there is shown an exemplary mattress M, which has a generally planar first surface 12 and a parallel generally planar second surface 14. The generally planar first and second surfaces 12, 14 are spaced apart at a uniform distance d defining the depth of the bedding product. The mattress M also has a pair of opposed generally planar, parallel end surfaces 16 which are spaced apart from one another a distance L which is the length or longitudinal dimension of the mattress. Similarly, the mattress has a pair of opposed generally planar side surfaces 18 which are spaced apart from one another and generally parallel. The distance between the opposed side surfaces 18 is equal to the width or transverse dimension W of the bedding or seating product. As illustrated in FIG. 2, the mattress M may be horizontally oriented so that the first and second surfaces are generally horizontal. Alternatively, the bedding product may be oriented such that the first and second surfaces are generally vertical, although such an orientation is not illustrated. Other orientations may be utilized in accordance with the present disclosure as well.

The mattress M is shown being supported by a plurality of spaced rollers 20. However the mattress M may be supported by any number of different mechanisms such as an endless conveyor belt. A first web 22 of extruded plastic film is wound about a first web roll 24. The first web 22 has a pair of opposed side edges 26, the distance between the side edges 26 defines the width of the first web. The first web 22 is a unitary piece of plastic and may have a uniform thickness or a variable thickness. A second web 28 of extruded plastic film is wound about a second web roll 30. Like the first web, the second web 28 has a pair of opposed side edges 32, the distance between the side edges 42 defining the width of the second web. As seen in FIG. 2, the widths of the first and second webs 20, 28, respectively, are approximately identical, although they need not necessarily be so.

As illustrated in FIG. 2, the first web roll 24 is spaced below the second web roll 30. A pair of spaced rollers 40 and 42 are located between the web rolls 24, 30, respectively and slightly in front thereof. However, the web rolls 24, 30 may be at other locations not specifically illustrated as may be desired in other packaging machines. Similarly, the location of the rollers may be changed from the locations without departing from the scope of the present disclosure. Exemplary mattress packaging machines suitable for use in the present disclosure are disclosed in U.S. Pat. No. 7,383,676, incorporated by reference in its entirety, can be readily configured to provide the excess material and the gripper openings.

The first and second webs 22, 28 are pulled from the first and second web rolls 24, 30, respectively, passed between the spaced rollers 40 and 42 and past the mattress M. The mattress M is oriented so that the end surfaces 16 of the mattress M and transverse dimension of the bedding product are generally parallel the opposed side edges 26, 32 of the aligned first and second webs 22, 28, respectively. The first web 22 of extruded plastic film is passed under the surface 14 of the mattress M slightly below the surface 12 of the mattress M. Similarly, the second web 28 is passed over the second surface 14 of the bedding product 10 slightly over the second surface. Each of the first and second webs are pulled in the direction of arrow 44 across the entire width W of the mattress M.

As the first and second webs 22, 28 are being pulled off of the first and second web rolls 24, 30, respectively, the first web roll 24 rotates in the direction of arrow 54 about a transversely extending axis, and the second web roll 30 rotates in the direction of arrow 56 about a transversely extending axis. As illustrated in FIG. 2, the first and second web rolls 24, 30 rotate in opposite directions. Contact between the first web 22 and the first roller 40 causes the first roller to rotate in a direction opposite to the direction of rotation the first web roll 24 (see arrow 54). Similarly, as the second web 28 passes over and contacts the second roller 42, the second roller rotates in the direction opposite to the direction of rotation of the second web roll 40 (see arrow 56).

Once a sufficient length of the first and second webs 22, 28 are pulled from the first and second web rolls 24, 30, respectively, pass between the first and second rollers 40, 42, respectively, and across the width of the mattress M, the first and second webs are cut with a cutting instrument (not shown). The length of the first and second webs across the width of the mattress are configured to provide excess material on the opposing peripheral sides of the mattress M, i.e., opposed generally planar side surfaces 18. Alternatively, excess material may be provided for opposing planar side surfaces 16 by itself, or in combination with excess material provided on opposing side surfaces 18. As shown more clearly in FIG. 3, excess material is designated by reference numeral 60 and refers to an amount sufficient to provide two seams: a first seam 60 abutting or in close proximity to the side surfaces 16 and 18, and a second seam 62 spaced apart from the first seam and at a distance effective to provide one or more gripping holes 66 therein. In FIG. 3, the excess material 60 is shown only at opposed generally planar side surfaces 18 although as discussed above, the excess material 64 defined by the first and second seams could extend about the entire periphery of mattress M or selected ones of the generally planar side surfaces 16 or 18.

The cutting instrument is not intended to be limited and may be a knife, a laser, a heated bar, a cutting wheel, or the like. The cutting instrument passes transversely across the width of the first and second webs 22, 28 so as to create first and second pieces of extruded plastic film from the first and second webs. The first and second pieces of extruded plastic film are located on opposite sides of the bedding product and extend beyond the periphery of the bedding product in order for the first and second pieces to be joined together about the periphery of the bedding product and to provide excess material about at least one of the selected opposed generally planar side surfaces 16, 18.

The final step in the method of packaging the mattress M in accordance with the present disclosure is to form the seams in the pieces of extruded plastic film 22, 28 together about the periphery of the bedding product with a seam 62 and 64 such as is shown in FIG. 3. Because the webs 22, 28 can be cut to have equal dimensions, the seam 62 about the periphery can extend halfway up the end and side surfaces of the bedding product but may be located in other positions as well. The seams may be formed using any conventional method including staples, glue, etc. but are preferably welded or heat sealed together.

The joining of the first and second pieces of extruded plastic film may be accomplished using any of numerous methods. For example, one or two spaced apart welding bars may be located along the opposed generally planar side surfaces 16 and/or 18 of the mattress. The welding bars are heated to a sufficient temperature in order to melt the plastic film of the first and second webs together.

The extruded plastic film used in accordance with the method of the present invention may be any plastic material. One type of plastic material which has proven to work well using the present invention is high density polyethylene. However, this application is not intended to limit the plastic material used in accordance with the present invention.

Once the cut webs 22, 28 of extruded plastic film are joined together along all four sides of the bedding product, the result is a single ply plastic film package with at least one of opposed generally planar side surfaces 16 and/or 18 of the mattress have excess material. One or more gripper openings 66 are then cut into the excess material. In one embodiment, the periphery of the gripper opening is sealed such as by welding.

The extruded plastic film used in accordance with the method of the present disclosure may be any plastic material. One type of plastic material which has proven to work well using the present invention is high density polyethylene. However, this application is not intended to limit the plastic material used in accordance with the present invention.

Although not specifically illustrated, the bedding product may be oriented so that the side surfaces of the mattress are generally parallel the side edges of the first and second webs. If the mattress is so oriented, the longitudinal dimension and side surfaces of the mattress are generally parallel the side edges of the first and second webs, respectively, and the resulting packaged product can be configured to provide excess material with gripper openings about generally planar first surface 12 and a parallel generally planar second surface 14.

Advantageously, the one or more gripper openings provide built-in gripping points, which markedly improve handling and transport of the packaged bedding product.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

What is claimed is:
 1. A packaged bedding product having a depth defined between opposed first and second surfaces, a length defined between a pair of opposed end surfaces and a width defined between a pair of opposed side surfaces, said bedding product being encased in a plastic film package, said plastic film package comprising: a first plastic film; a second plastic film; a first seam joining the first plastic film to the second plastic film, wherein the first seam is disposed about a periphery of the bedding product; at least one second seam joining an end of the first plastic film to an end of the second plastic film, wherein the at least one second seam is spaced apart from the first seam to define excess plastic film material therebetween, and wherein the at least one second seam and excess plastic film material is provided at one or more of the opposed end surfaces and/or one or more of the opposed side surfaces of the bedding product; and one or more gripper openings disposed in the excess plastic film material.
 2. The packaged bedding product of claim 1, wherein said length is greater than said width.
 3. The packaged bedding product of claim 1, wherein the first and second seams are thermal welds.
 4. The packaged bedding product of claim 1, wherein the bedding product is a mattress.
 5. The packaged bedding product of claim 1, further comprising a third seam joining the first plastic film to the second plastic film about each one of the gripper openings.
 6. The packaged bedding product of claim 1, wherein the first plastic film and the second plastic film have a variable thickness.
 7. The packaged bedding product of claim 1, wherein the excess plastic film material defined by the second seams is provided at the pair of opposed end surfaces defining the length of the bedding product.
 8. The packaged bedding product of claim 1, wherein the excess plastic film material defined by the second seams is provided at pair of opposed side surfaces defining the width of the bedding product.
 9. A process of forming a packaged bedding product having a generally planar first surface and a parallel generally planar second surface, the process comprising: simultaneously passing a first web and a second web of plastic film past the first and second surfaces on opposite sides of the bedding product; cutting the first and second webs so as to create first and second pieces of the plastic film about the bedding product; joining the first and second pieces of plastic film together about a periphery of the bedding product to form a first seam enclosing the bedding product in a plastic film package; joining an end of the first piece to an end of the second piece to form at least one second seam, wherein the at least one second seam is spaced apart from the first seam to define excess plastic film material therebetween; and forming hand-hold openings in the excess material.
 10. The process of claim 9, wherein forming the hand-hold openings in the excess material further comprises joining the first and second pieces of plastic film about a perimeter defining the hand-hold opening.
 11. The process of claim 9, wherein joining the first and second pieces of plastic film to form the first seam and at least one second seam comprises thermally welding the first piece to the second piece.
 12. The process of claim 10, wherein joining the first and second pieces of plastic film about the perimeter defining the hand-hold opening comprises thermally welding the first piece to the second piece.
 13. The process of claim 9, wherein the first and second pieces of plastic film have a variable thickness.
 14. The process of claim 9, wherein the first and second pieces of plastic film is a polyethylene material. 